Plasma apparatus for carrying out high temperature chemical reactions

ABSTRACT

In the process of carrying out high temperature, chemical reactions including reductins for producing elemental metal powders, especially refractory metals; chlorinations for producing halogens and for chemical synthesis in general using a plasma genertor, the reactant or reactants feed material is introduced into the reaction zone of the apparatus and the effluent from the reaction zone is directed into a quenching zone through a selectively variable passageway or orifice in a manner that permits in the reduction process separation of the desired reaction product from the effluent hot gas stream and the continuous collection of the reaction product in a collection zone wherein in some instances, the reaction product is of a selected characteristic, controlled by the maintenance of certain operational parameters, including a selected differential fluid pressure in the reaction and collection zone as well as reaction and collection zone temperatures. Apparatus for carrying out the high temperature chemical reactions is disclosed.

nited States Patent 1 1 Davis et a1.

[ Oct. 8, 1974 Roy L. Blizzard, Huntington Beach, all of Calif.

[73] Assignee: Plasmachem, Inc., Santa Ana, Calif. [22] Filed: Mar. 19, 1973 [21] Appl. No.: 342,699

Related US. Application Data [60] Continuation-impart of Ser. No. 303,707, Nov. 6, 1972, abandoned, which is a division of Ser. No. 125,589, March 18, 1971, Pat. NO. 3,738,824.

Sheller et a1 75/.5 BB

Neunschwander 75/.5 BB Houseman 250/547 Primary Examiner-T. M. Tufariello Attorney, Agent, or FirmMahoney, Schick & Cisla [5 7] ABSTRACT 1n the process of carrying out high temperature, chemical reactions including reductins for producing elemental metal powders, especially refractory metals; chlorinations for producing halogens and for chemical synthesis in general using a plasma genertor, the reactant or reactants feed material is introduced into the reaction zone of the apparatus and the effluent from the reaction zone is directed into a quenching zone through a selectively variable passageway or orifice in a manner that permits in the reduction process separation of the desired reaction product from the effluent hot gas stream and the continuous collection of the reaction product in a collection zone wherein in some instances, the reaction product is of a selected characteristic, controlled by the maintenance of certain operational parameters, including a selected differential fluid pressure in the reaction and collection zone as well as reaction and collection zone temperatures. Apparatus for carrying out the high temperature chemical reactions is disclosed.

28 Claims, 13 Drawing Figures PAIENTEI) 8W4 3. 840, 750

EIIEET 10F 6 FIG. v FIG. 2. GENERATE I i j PLASMA I INJECT 2 FEED V MATERIAL I DIRECT REACTANTS BI FLUID FLOW INTO COLLECTOR OF VARIABLE VOLUME 7 32 CONTROLLABLY IG RESTRICT FLUID FLOW FROM COLLECTOR 7[I8 I I VARY COLLECTOR VOLUME 30k TO ALLOW ELEMENTAL METAL FORMATION RECOVER HIGH PURITY METAL OF CONTROLLED PARTICLE SIZE Pmmwnm w 3.840.750 SHEET u 0F 6 Fig.7. I 2 6 O Fig.7a.

PATENTED 74 SHEEI 5 BF 6 PATENTEU 74 Nmm vmm

SHEET 8 BF 6 PLASMA APPARATUS FOR CARRYING OUT HIGH TEMPERATURE CHEMICAL REACTIONS CVRQSS-REFERENVCETQ RELATED APPLICATION BACKGROUND OF THE INVENTION This invention pertains to methods and apparatus for carrying out high temperature chemical reactions wherein high yields of reaction product is obtained. The invention is generally directed to reductions, halo-, genations and chemical synthesis reactions but is not limited thereto. Exemplary reduction reactions include reduction of refractory metal compounds to the elemental metalstate. Refractory metals include, by way of example and not limitation, tantalum, tungsten, molybdenum and columbium. In some instances, formation of alloys of these metals with such other metals, such as tin, etc., is possible through simultaneous reduction of the constituents. Other applications of the invention include halogenation of various oxides, for example, columbium oxide to columbium chloride. The invention also pertains to the high temperature reaction or synthesis of chemicals, for example, the synthesis of acetylene, benzine and other hydrocarbons or products which are normally carried out under high temperatures. v

More particularly, the invention relates to method and apparatus for producing relatively high purity reaction products of selected characteristics involving high percentage yields and selected characteristics, all in a commercially feasible manner.

More specifically the invention is directed to the processes and apparatuses for producing reaction products, as for example, metal powders, chemicals and halogenated metals using a plasma generator for the energy required to carry out the reaction.

For example, metallic halides and oxides are reduced, metal oxides halogenated and hydrocarbons and other compounds synthesized using a plasma generator to produce reaction products of the elemental metal, metal halides or chemical compounds and are recovered in relatively pure forms and in quantities which have not been heretofore possible by plasma processes.

The prior art of gas-discharge physics is well aware of the means for conducting chemical reactions using a plasma flow or plasma jet. The chemical reactions with which this invention is involved are similar to those of the prior art but are specially directed to reductions of metallic compounds with reductants such as, for example, hydrogen or carbon; halogenations of metal oxides and hydrocarbon synthesis. Other reactions will readily suggest themselves to those of ordinary skill in the art as the disclosure proceeds herein. """The" temperatures generated in a plasma generator are relatively high and the reactions carried out thereby have heretofore been primarily of a non-commercial nature, for a variety of reasons, some of the more common being because the plasma generators could not support sustained reactions without deleterious effects, for example, plugging of the anode chamber, or could saturate??? b ratsix u i of desired endpro ucts, which in most instances were not of a quantity or quality needed in commercial manufacturing processes, or because the product lacked certain essential characteristics, such as, for instance, size of the reaction product where reduction to elemental metals are concerned.

Among others, the present invention provides process and apparatus for the manufacture of elemental metals of the groups IVb, Vb, and Vlb of the Periodic Table wherein a compound of said metals is reacted in a high temperature reaction zone produced by a plasma generator, in a manner to produce heretofore unavailable quantities of the elemental metal of selected particle size at a satisfactory purity level, or a halogen of said metal is produced which itself may be further reacted to obtain the metal per se.

For instance, a present commercial need exists for tantalum powder of substantially pure form and having a particle size sufficiently large for the formation of electrodes for capacitors, of the dry or liquid type. The elemental metal, such as tantalum, obtained in the practice of the herein disclosed invention is of capacitor grade quality from which capacitors may be formed. In other instances, a metallic oxide may be halogenated and further reducted to the elemental method according to the practice of the invention.

According to the invention hydrocarbons such as acetylene, benzine and other compounds requiring high reaction temperatures may be synthesized.

The following examples of the practice of the invention are illustrative. In the formation of elemental tantalum, a metallic halide such as tantalum pentachloride or potassium fluotantalate is reduced in the plasma reactor utilizing a reductant such as hydrogen, in a process wherein purity of the obtained tantalum is at a high level. The particle size of the metal is selectively controlled all in a commercially sustainable and feasible process producing copious amounts of the elemental metal at high percentage yields. In the formation of a metallic halide, an oxide such as columbium oxide may be chlorinated to columbium chloride. In the synthesis of chemical compounds acetylene is synthesized from methane.

OBJECTS AND SUMMARY OF THE INVENTION It is an object of the present invention to provide a method and apparatus for carrying out high temperature chemical reactions.

It is another object of the invention to provide method and apparatus for obtaining usually high temperature produced reaction products of high purity in high yields.

It is still another object of this invention to provide method and apparatus for the production of elemental metal powders in a range of selected particle sizes, shapes and surface conditions, wherein the process may be continuous.

It is still a further object of this invention to provide method and apparatus for the production of elemental metals using a plasma generator.

It is still a further object of this invention to provide method and apparatus for the high temperature halogenation of oxides.

It is still a further object of the invention to provide method and apparatus for the high temperature synthesis of chemical compounds.

It is still another important object of this invention to recover high temperature reaction products using a plasma generator wherein selected fluid pressure control between a heated zone and a recovery zone is maintained to obtain the desired end product.

It is still a more specific and further object of this invention to provide a method and apparatus for reducing metallic compounds to the elemental metal compound form using a plasma generator.

It is still a more further specific object of this invention to provide method and apparatus for the reduction of metallic halides, oxides to the elemental metal.

It is still a further object of the invention to provide method and apparatus for the halogenation of metal oxides.

It is still another and further object of the invention to provide method and apparatus for the chlorination of at least two different metallic oxides.

It is a further specific object of the invention to provide method and apparatus for the chlorination of columbium oxide and the subsequent reduction thereof to elemental columbium.

It is still another further object of this invention to provide a method and apparatus for the reduction of one or more metallic halides using a plasma generator wherein the reactant is introduced into a reaction zone of the plasma generator and the elemental metal and/or alloy is collected in a collection zone of the apparatus.

It is still a more specific and further object of this invention to provide a method and apparatus for the production of elemental metal and/or alloy with a plasma generator wherein the effluent from the reaction zone flows through a collection zone wherein selective control of differential pressure and temperature between said zones permits particle formation of the metal in a selective manner.

It is still a more specific and further object of this invention to provide method and apparatus for forming refractory metal compounds for example, tantalum, tungsten, molybdenum and columbium compounds to the elemental metallic state wherein such metals are of high purity and of selected range of particle sizes on a continuous basis.

It is still an even further more specific object of this invention to provide a plasma process for high temperature chemical reactions wherein the reactant and/or reactants are introduced downstream of the anode or exhaust of said generator and the effluent flow from the generator is directed through a selectively variable passageway in a selectively controlled manner into a collector zone wherein reaction product is collected.

It is still a further and even more specific object of the invention to provide a method and apparatus for the high temperature synthesis, for example of acetylene, benzine and other hydrocarbons and chemicals in a hydrogen plasma process wherein the reactant is introduced downstream of the anode or exhaust of the generator and the effluent from the reaction zone is passed through a temperature gradient zone within which a collector is positioned to selectively vary the passageway for the effluent flowing through said temperature gradient zone.

Other objects and advantages of the invention will be apparent from the following specification and the accompanying drawings which are for the purposes of illustration only.

Basically, in an exemplary embodiment, the method of the invention comprises a process for reduction, halogenation or chemical synthesis wherein a reactant and/or reactants are introduced into a plasma, downstream from the anode or exhaust of the generator and the effluent flow from the reaction zone is directed through a selectively variable passageway, in a selectively controlled manner, into a collecting zone wherein reaction product, in relatively pure form and having a selected characteristic is obtained while maintaining selective control of the efiluent flow.

One means of conducting the above process is through the use of a plasma generator apparatus comprising the combination of a reactor having a cathode and an anode within which a plasma arc is generated. Said generator communicates with a reaction zone member into which reactant feed material is introduced. A quench member comprising said reaction zone member directs the flow of effluent therefrom through a directed path and a collector means is positioned within the quench member and path, thereby forming a selectively variable passageway through which the effluent flows. By maintaining a selected pressure differential between the reaction zone and the collection zone, and by maintaining selected temperatures in the reaction zone and collection zone, a selected product of reaction is obtained from the efflu- 6m.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 depicts a flow diagram for practice of one method of the invention;

FIG. 2 schematically illustrates an exemplary apparatus for the practice of the method disclosed in FIG. 1;

FIG. 3 is a fragmentary view of a plasma generator utilizing a specific embodiment of the invention;

FIG. 4 is a fragmentary view similar to the reactor shown in FIG. 3, but modified for practice of the invention on a continuous basis;

FIG. 5 is a simplified elevational view of another embodimentof the apparatus useful for the continuous production of reaction products, such as for example, elemental metals;

FIG. 6 is a view taken along the line 66 of FIG. 5;

FIG. 7 is a view taken along the line 77 of FIG. 6;

FIG. 7A is a schematic view of one of the alternative constructions of an element of the apparatus shown in FIG. 7;

FIG. 8 is a view taken along the line 8-8 of FIG. 5;

FIGS. 9 and 10 schematically illustrate the operation of the apparatus shown in FIG. 5;

FIG. 11 is an elevational view,- partially in section, showing an apparatus for continuous practice of the invention; and

FIG. 12 is atop view of the apparatus shown in FIG. 11, with the top plates removed and parts omitted for the purpose of clarity.

DESCRIPTION OF THE BEST EMBODIMENTS CONTEMPLATED As an introduction, a brief general description of the inventive method and apparatus will be beneficial in understanding the scope and breadth of the invention.

to FlGSFl and 2, one specific method of the invention process and exemplary apparatus for practicing the process are illustrated. It should be understood that the specific process described is for illustrative purposes only. Thus, while the invention will be described for the reduction of metal halides, it is also applicable to the halogenation of metal oxides and the high temperature synthesis of chemicals, as will more fully appear hereinafter.

The plasma generator 2 is generally of the conventional type having the usual cathode and anode suitably connected to a power supply so that a potential across the anode zone 4 is produced. The introduction of a stabilizer or inert gas or alternatively, of a reactant gas, into the anode zone 4 produces a reactive plasma generally within anode zone 4 extending axially downward in direction of the arrow shown in FIG. 2.

Thus far, the plasma generator described is wholly of prior art type. Feed material, comprising a refractory metal compound and from which elemental metal is to be obtained, is fed via inlet 6 by itself (or in some instances with a feeder or carrier gas, as will become apparent) so that the feed material is introduced downstream of the anode and approximately into the generated plasma. Feeding the feed material in this manner effectively prevents reaction product buildup on the interior anode surfaces.

Where a stabilizer gas is used to generate the plasma, the carrier gas for the feed material may also comprise a reactant gas such as hydrogen, where the refractory metal compound is to be reduced, and/or a reactant gas may be introduced adjacent the point of feed material introduction as by meansof reactant gas inlet 8. The feed material and reactant gas are carried by the plasma into what may be considered an axially extending reaction member 10. Member 10 is made ofa material which is preferably inert to the reactants and reaction conditions (one such material being tungsten). Other refractory metals will also suffice and will be chosen for their ability to withstand the high temperatures involved; will not suffer erosion and will not conraminatethe e emeptalm a Sought to b recovered.

The member 10 generally defines the principal reaction zone 12 from which effluent flows through the lower portion 14 of member 10 and into a collector means generally designated 16 and through an outlet 18 provided in the wall of quench member 20.

As illustrated, the reaction zone 12 and a collector zone 22 are located within the confines of quench member 20 of a fluid-cooled type. Collector means 16 comprises, in this instance, a cylindrical, sleeve-like member 24 also of an inert material, the wall thereof extending upwards, into substantially fluid-tight engagement with horizontal portion of the outwardly flared wall 14 of member 10. Disposed within sleeve 24 generally defining collection zone 22 is the other portion of collector means 16, collector cup member 26 having a peripheral edge 25. It will be noted that a temgegature gradient is established between the elongate upper portion of member 10 and the flared wall portions 14 thereof.

Collector cup 26 is generally of configuration having a major peripheral configuration coinciding with the flared wall portions 14 of member 10. A support member 28 is secured to the bottom of collector cup member 26 and extends through an aperture 30 provided in hahqttsmwa zsfsuensh member i manner that allows axial movement of collector cup 26 in the direction of the arrow, substantially through the entire length of sleeve 24. Theoretically, member 10, in combination with the interior surface of collector cup member 26, generally defines the boundaries of reaction zone 12, although the principal reaction of the reactants take place upstream of the collector cup member 26.

For obvious reasons, the materials of construction of the member 10, at least the interior of sleeve 24, cup member 26 and support member 28, are fabricated of materials inert to the reaction conditions, reactants and resultant elemental metal.

At initiation of the process, the cup member 26 is positioned so that the passageway 32 is a small one from about 0.0312 to 0.500 inch, with an initial spacing of about 0.1250 generally being sufficient. After a period of time, elemental metal from the effluent flowing through the passageway 32 and in the manner shown by the arrows, begins to build up in sponge form on and about the edge 25 and grows to the outer extremities thereof to the interior wall of sleeve 24 substantially as shown. The sponge is initially donut-shaped and be cause of its position, impedes the flow of effluent through passageway 32 but performs a beneficial function in that the effluent when flowing through the interstices of the sponge deposits still more metal particles allowing for greater recovery.

Periodically, the support member 28 is moved axially downward to maintain the passageway 32 sufficiently large to allow passage of the effluent and to allow further buildup of the metallic sponge,'the height or depth of which will extend substantially the entire length of sleeve 24 to'thereby produce what may be considered a metallic sponge elongate donut of irregular cylindrical shape.

At the completion of the run, the collector 16 may be removed from the confines of quench member 20 and the elemental metal scraped off of the interior of the sleeve 24 and the surfaces of collector cup 26. The recovered elemental metal is of high purity and of unique characteristic having an apparent Fisher Sub sieve particle size within the range of from about 0.5 to 12 microns, and larger, depending upon the conditions under which the collection is carried out. Generally, particle sizes within the one to ten micron range will be formed. As will be more fully set forth hereinafter, the particle size of the recovered metal may be selectively controlled by varying the size of the passageway 32 through which the effluent of the plasma reactor passes.

in some instances, it will be desirable to produce submicron metal particles. The flow-through or waste effluent is withdrawn from the system through outlet 18 and may be passed into suitable heat exchangers, separators or other conventional recovery equipment.

The plasma generator should be adjusted to obtain a neutral gas temperature in the plasma reactor sufficiently high (1,800K to 5,000l() to obtain the desired chemical reaction. As a rule, the reaction is carried out under atmospheric pressure or slightly above.

Various gases may be used to stabilize the plasma, such as inert gases as for instance, helium or argon, or reactive gases as for instance, hydrogen, nitrogen or methane. The type of stabilizer gas used to generate the plasma and the power input to the generator will necessarily dictate the temperatures generated thereby.

The power input into a plasma generator will for the most part determine the intensity of the reaction generated in the plasma stream and may be varied, keeping in mind the aforementioned criteria.

In order to obtain proper mixing and to carry the feed material into the reaction zone, a carrier or feeder gas may be found to be desirable. The feeder gas may be one of the stabilizer gasses mentioned above or may be a reactant such as hydrogen where reduction of a metallic compound is contemplated. Thus, in some instances, one of the reactants such as hydrogen may be used to generate the plasma stream and also to carry the feed material into the reactor. This will be found to be desirable when considering that high yields using the method of the invention are obtained by having excess stoichiometric amounts of hydrogen available for the reduction.

Ease of conversion and the amount of conversion, where it is desired to reduce a refractory metal compound for example, such as tantalum pentachloride, to tantalum by reduction with hydrogen gas, are dependent on the excess hydrogen ratio over the stoichiometric amount required to obtain substantially complete conversion of the tantalum pentachloride to tantalum metal. Desirably excess hydrogen ratios are employed which provide substantially complete conversion at the particular reduction temperatures and pressures employed. A hydrogen excess of about 3 to 5 at a calculated temperature range of about 1,800K to 3,000K will permit substantially complete conversion.

Where it is desired to introduce the feeder material in the vaporized state with a carrier gas, preheating of the carrier gas may be necessary in order to feed material in the vaporized state. It has been found, however, in most instances that vaporization and/or preheating of feed material or the carrier gas is not necessary.

In most cases in the production of elemental metals, the reactant feed material will be a refractory metal compound from which the elemental metal is sought to be recovered. Thus examples of elemental metals which will be recovered generally include those previously mentioned and more specifically tantalum, molybdenum, tungsten and columbium or niobium. The halides of these metals as well as oxides are alsosuitable and will include such exemplary compounds as tantalum pentachloride, columbium pentachloride, tungsten pentachloride and molybdenum pentachloride. Generally, any of the compounds wherein the chemistry is generally known and has heretofore been demonstrated in the art will suffice in the practice of the invention. Hence, reduction to the elemental metals using carbon, sodium or other additives are also contemplated.

The purity of the elemental metal produced by the process of the invention is dependent to a great extent on the purity of the reactants, i.e. refractory metal compounds and the other reactants such as a reductant, for example hydrogen. Also playing an important role are the materials comprising the reactor and the apparatus in which the process is practiced. Thus, materials commonly used for high temperature applications and which are substantially chemically inert and resistant to the reactants at the particular process conditions with the particular feed material being used, will be found to be desirable. I

Desirably, the reactor and collector portions of the apparatus will be fabricated of or lined with the elemental metals sought to be recovered or one of the other commonly and commercially available refractory metals such as for example, tungsten. To insure high purity, the apparatus may be cleansed with an inert purge gas such as argon or helium, prior to commencing the practice of the method of the invention. These matters as well as others are generally well known in the metallurgy art and need not be delved into in great detail herein.

Referring now to FIG. 3, a specific apparatus and method of carrying out one embodiment of the invention will be described. A reactor of the conventional type having the usual reactor head 42 (only the anode portion of which is illustrated). Anode structure 44 is appropriately water cooled and is positioned in axial alignment with feed collar member 46 also appropriately water cooled by means of water inlet 48 and appropriate water lines not shown. Collar 46 is annular in configuration and is provided with an inner liner 50 of an inert material. Feed material may be introduced by means ofa plurality of lines or one feed line 52 through feed collar 46. The introduction of additional reductant, or the like through lines, not shown, may also be provided. The primary stabilizer gas and reductant inlets are provided in the reactor head 42 above the anode structure 44 and are not shown herein.

Positioned below anode structure 44 is quench fixture or tank 54 of the water-cooled type being provided with water inlet 56 and water outlet 58 so that cooling fluid may circulate in conventional fashion. A viewport 60 may be provided in the wall of quench tank 54. Other viewports located generally at 62, not shown, may also be provided so as to be able to view the interior of the quench member 54. Quench tank 54 is secured to reactor head 42 in fluid-tight relationship by means of a header 64 in conventional fashion and is provided with bottom wall 66 having removable cover 68 which is provided with through hole 70 for purposes which will be described. Effluent outlet 71 is provided in the side wall of quench member 54.

Positioned downstream of anode structure 44 and collar 46 is a reaction zone member, generally designated 72, comprising throat member 74 having an upper flanged portion 76 supported by means of support collar 78 provided for that purpose. Secured to the lower end of throat 74 of member 72 is cup member 80 of bell-like configuration disposed about throat 74 so that the terminus portion 82 of throat 74 extends well into the interior of cup 80. Cup 80 is here shown as supported by plate 84. Plate 84 is provided with a central opening 86 congruent in size and shape with the inside peripheral edge of cup member 80.

Plate 84 is supported from the interior wall 88 of quench tank 54 by means of ring support 90 which is welded or otherwise secured to interior surface 88.

Positioned within the interior of quench tank 54 and below plate 84 is liner 92 comprising a tubular sleeve having carbon wall 94 and inner lining 96 of an inert material. Liner 92 may be ring 98 in the manner shown.

Disposed within the confines of liner 92 is collector cup member 100 of general cup configuration having a flanged edge 102 and being supported from the bottom thereof by means of rod 104 secured by means of bushing and pin assembly 106. Rod 104 extends through bore 70 in removable cover plate 68 and supports cup member 100 in an axially shiftable manner-so that cup 100 may be moved toward and away from plate 84 in an axial direction substantially the entire length of liner 92. It will be noted that the surface of plate 84 inwardly directed toward cup 100 forms with the outer surface 108 of lip 102 a passageway or orifice generally designated 110.

The throat 74, bell-like member 80, plate member 84, collector 100, rod 104, bushing and pin assembly 106, as well as inner lining 96, are preferably made of a refractory material and one that is inert to the reaction conditions which are to be carried out in the reactor 40 and which will not erode under the high temperature, and high fluid flow conditions. In the preferred case, tungsten is a suitable material but other materials such as molybdenum and the like will also suffice.

The throat member 74, bell-like member 80 and collector cup 100 generally define a high temperature or reaction zone 112 wherein a refractory metallic compound, for example, is reduced by a reductant such as hydrogen. Theoretically, most of the chemical activity takes place within the throat member 74. However, because of the turbulent conditions within the zone defined by members 74, 80 and 100 reaction may take place throughout. The collector 100 in conjunction with plate 84 and inner lining 96 form what may be considered a collection zone 114 generally within the area of the orifice or effluent passageway 110.

In practice, the reactor 42 is energized to produce a plasma generally in the area designated 116 proximate to the feeder material inlet (or inlets) 52. So that ease of viewing may be had through the viewports; and generally positioned at 62, not shown, a gas such as hydrogen may be injected at these port sites so as to keep the ports sufficiently cooled to permit visual observations of the interior of quench tank 54 above and below plate 84. As feed material is introduced directly into the plasma for example, a feed material such as tantalum pentachloride, which is carried by a carrier gas such as argon, chemical reaction because of available reductant and extremely high temperature takes place within zone defined by members 74, 80 and 100 but theoreti-' cally predominantly within the confines of throat member 74.

An effluent from and within thereaction zone comprising vaporized elemental tantalum, hydrogen, hydrogen chloride from the reducing reaction, as well as unreacted tantalum pentachloride and argon, flows downward from the confines of throat 74, through a temperature gradient, into bell member 80 whereat because of the substantial pressure and temperature difference, a deposition of elemental tantalum begins to occur. The'effluent passes through the passageway 110 through the length of the liner 92 and thence out through the outlet 71 of the quench tank for further treatment and/or recovery processing.

As the reaction is initiated, the collector cup 100 is positioned relative to the interior surface of plate 84 so as to provide a gap distance of about one-eighth inch enlh intent! .sutf ss. 1.9.8. 99) fs s 102 supported by bottom support and the interior surface of plate 84. As the effluent follows the path heretofore described, elemental tantalum begins to form predominantly on the interior surface 108 of edge 102 is significant quantities. After a time, tantalum sponge is formed tending to completely block the gap or passageway 110 and hinder effluent flow to the extent that increasing back pressure begins to develop within reaction zone. When this occurs, the collector cup 100 is moved axially downwards (manually or otherwise) by means of rod 104 so as to maintain a pressure differential between reaction zone and the interior of liner member 92 or collection zone 114 of about 0.5 to 5.0 psig with a preferred range being about 2 to 3 psig. Obviously, instrumentation, not shown, is provided for this purpose. As the tantalum sponge begins to form and grow, more and more elemental tantalum is recovered in that the effluent must now also pass through the interstices of the porous sponge of elemental metal to thereby deposit more elemental metal therein and theron.

In the apparatus depicted in FIG. 3 continuation of the process is carried on until the collector cup 100 is at or near the lowermost edge of liner 92 at which time the apparatus is shut down, allowed to cool and the tantalum removed. The recovered tantalum is found to have a particle size range considerably larger than the sub-micron particles heretofore recovered in the prior art and is recovered in copious quantities at overall yields of sponge in excess of 90 percent and at high purity levels. The refractory and other metals also exhibit unique physical properties heretofore unobserved in elemental metal production processes.

Referring now to FIG. 4, a'similar type apparatus as that depicted in FIG. 3 is schematically illustrated but differs therefrom in the respect that whereas the apparatus described in FIG. 3 only permitted batchwise refractory metal production, the apparatus depicted in FIG. 4 permits refractory metal recovery on a continuous basis.

The apparatus of FIG. 4 is essentially of the same omitted since this structure is essentially the same as shown in FIG. 3. It will be noted in this instance; that throat member 142 is slightly shorter than that previously described and upper cup member 144 is of slightly different shape than the bell-like member in the previously described apparatus. A shortened formation zone for the metallic sponge is achieved by providing a shortened liner 146 adequately supported from the interior walls of the quench tank as by means of supports 148 and 150.

A collector 152 is of generally more cylindrical shape than the collector previously described.

Once the elemental metal has deposited in the form of a sponge (donut shaped'or porous cyclinder, shown on the exterior of collector 152 positioned in the phantom position) substantially the length of the liner 146, the collector 152 is moved to the phantom line position shown and a plurality or rods 156 are brought into the relative positions shown. When the collector 152 is moved upwards back into the full line position shown, the rods engage the sponge donut breaking it free or scraping it from collector 152 allowing it to fall to the bottom of the quench tank whereat is positioned a legsupported receptacle or dish 158 which receives the dislodged metal sponge.

Thus, there is no need to cool down the reactor 140 each time the donut sponge formation is formed, and the only limitation to continuous operation of reactor 140 is the capacity of receptacle or catcher pan 158. However, and as is obvious to those of ordinary skill in the art, an automatic conveyor, rake or any such means may be employed for removing both the pan 158 and the accumulated elemental metal contained therein from the bottom of the quench tank without difficulty.

As was the case in the apparatus depicted in FIG. 3, the rods 156 and the pan 158 are of inert materials such as for example, tungsten, so as not to contaminate the elemental metal recovered. The mode of operation of the device 140 is essentially the same as that described for the device with the exception hereinbefore noted.

A plasma generator was constructed according to principles well known to the state of the art and was positioned in axial alignment with a feeder ring plate or member such as 46 of stainless steel material and having four feeder material inlets angularly disposed as shown in FIG. 3.

Supported on the graphite spacer 78 was a throat member 74 of tungsten having an inside diameter of 2.1875 inches, a wall thickness of 0.0937 inch and a length of about 3.25 inches.

A tungsten bell member 80 having an inside diameter of approximately 4.500 inches and being about 3.25 inches long with a 0.125 inch wall thickness was positioned as shown in FIG. 3 with the lower extremity of throat 74 projecting about 1.5 inches into the bell member 80.

Bell member 80 was supported on plate member 84 being of tungsten material 0.125 inch thick, and a diameter of 11.500 inches with a central aperture of 4.500 inches opening into the interior of bell member 80. Plate 84 was supported within the quench member 54 by a stainless steel ring 90, A X /2 inch, tack welded to the inner wall of quench tank 54.

The liner 92 comprised graphite sleeve 94 of 0.375 inch wall thickness and was approximately 6.3750 inches in diameter, with an approximate length of about 12 inches. An interior surface 96 of tungsten approximately 0.020 inch thick completed the interior of the liner member 92. Member 92 was supported by a stainless steel ring such as 98 and as shown in FIG. 3.

The collector cup of member 100 comprised a cup of approximately 4.500 inches inside diameter, a length of 4.0 inches, and was fabricated of tungsten having a wall thickness of 0.125 inch. The support rod 104 was a 0.3750 inch diameter tungsten shaft secured to cup 100 by means of tungsten bushing and tungsten pin assembly 106 substantially as shown in the figure. The outlet passageway 71 from quench tank 54 through which effluent flowed, was about 1.0 inch in diameter.

Using an apparatus as immediately described above,

a series of experimental runs was conducted wherein the effluent passageway 110 was varied from about one-eighth to one-fourth inch to vary the differential pressure between reaction zone generally indicated at 112 and the collection zone 114 within the interior of the liner member 92. This procedure also affected temperature conditions within reaction zone 112. By varying the passageway 110, larger or smaller elemental metal particles were selectively obtained by means of forming a metallic sponge cylinder or donut approximately 15 centimeters in diameter, 2 centimeters thick and a length which varied depending upon the length of each run.

Average temperature conditions in the reaction zone 112 were calculated to be within the range of about 1,8002,850K and the temperature of the flow through or waste effluent was measured to be within the range 200-550C. From the quench tank outlet 71 the effluent was put through a cyclone recovering apparatus of conventional type to obtain additional elemental metals of sub-micron size.

The in situ formed elemental metal sponge was found to have individual particles exhibiting a necking property to produce inter-connected particles forming a porous structure and which upon grinding and sieving produced elemental particles or powder of the 1 to 10 micron size determined by gas permeability using the Fisher sub-sieve sizer technique. The unique configuration of the metallic sponge was ascertainable by means of photomicrographs clearly indicating the unique structural characteristics of the elemental metals obtained in the practice of the hereindisclosed invention. The photomicrographs also revealed the porous structure in detail. Thus revealing how the effluent gas could continue to flow through the sponge.

Analysis of the various metals obtained indicated that refractory metals of extremely high purity levels were obtained. In order to verify in several of the instances what material was being collected in the metallic sponge form, samples were determined to exhibit X-ray diffraction patterns identified as molybdenum, tantalum and tungsten respectively, having a cubic or crystaline structure.

As indicated, using the reactor already described, a series of runs was made to obtain elemental tantalum. The feed material was tantalum pentachloride and the results are accurately depicted in the following Table I, Table II, and Table III.

TABLE I Feed and recovery Gas Percent of Power total (t) 1 1 Total conversion Head Cal. stab. Feed rate Feed contained Ta Ta recovered Kw. Kw. efly, reaction, flow, Feed carrier contained time, Ta, sponge, fines, in sponge Run number (gross) (net) percent K s.c.t.h. flow, s.e.f.h. Ta, lb./hr. hours pounds pounds pounds form 76. 6 26. 6 37. 7 2, 870 663 148 (He) 32. 6 0. 47 7. 74 6. 67 1.07 86.2 71. 4 26. 7 37. 4 2, 956 663 178 (He) 17. 3 0. 75 6. 59 4. 15 1. 88 63. 0 63. 0 26. 5 42.0 2, 600 800 266 (He) 21. 8 0.67 7. 41 4. 13 3.34 56. 0 65. 3 40. 6 62. 2 ,980 883 198 (Ar) 43. 4 0. 21 4. 52 1. 98 0. 84 44. 0

62. 2 35. 4 56. 6 2, 825 883 198 (Ar) 12. 5 0. 48 4. 06 2. 97 0. 71 73. 65. 2 37. 8 58. 0 2, 850 883 108 (Ar) 18. 3 0. 48 4. 43 3. 0. 48 80. 3 66. 4 37. 8 57. 0 2, 886 883 108 (Ar) 23. 6 0. 23 3. 41 2. 72 0. 20 X0. 3 65. 8 37. 0 56. 3 2, 865 883 lllil (Ar) 21. 8 0. 37 4. (l8 2. 51 1.14 61.6 64. 8 30. 5 47. 0 2, 800 773 1% (Ar) 16. 7 0. 36 4. 12 1. 75 1. H6 47. H 64. 5 36. 1 55. 8 2. 842 883 film (Ar) 21. 2 0. 35 3. 76 3. 00 0. 73 83. 5 61. 8 34. 7 56. 1 2, 800 833 108 (Ar) 21. 1 0. 34 3. 67 2. 80 0.41 73. 4 65.0 37.2 57. 2 2, 856 883 101i (Ar) 24. U (l. 37 4. 58 3 16 0. 38 86. 5 61. 6 36. 4 51. 5 2, 710 883 108 (Ar) 24. 3 0. 40 4. 88 4. 10 0. 50 81M) 64. 4 34. 2 53. 1 2, 800 883 198 (Ar) 22. 0 0.42 4. 73 3 03 1.03 83. ll

%" tungsten rods placed in efliuent flow below collector cup.

N0'rE.:t=0veral1 total conversion lncluding fines ranges from 62.0%98.2%.

TABLE IV l 0 i400 I000 I 400 l 600 Tests were conducted of electrical properties of capacitor anodesmade from tantalum powder produced from the practice of the invention. A commonly accepted criterion of quality of capacitor anodes is the 13 14 TABLE IL-AVERAGE CONDITIONS PER RUN S.e.f.h. gas To in feed Sponge Fines Power Cal. H2 Lbs. Lbs. Percent Lbs. Percent Kw. Kw. Efly react. H2 stoich. Feed Runs total Lbs/hr. total LbJhr. of feed total Lb./hr. of feed (gross) (net) percent temp. stab. multiple carrier Fthru N..- 4.2 10.87 3.16 8.23 76.1 0.76 1.97 18.0 64.2 35.7 55.0 2,823 883 15.22 1 198 Lthru N 4.73 12.12 4.03 10.33 85.0 0.67 1.70 14.1 63.7 35.9 56.4 2,889 883 13.6 1 198 Argon. .11.

TABLE III FISCHER SUB SIEVE Analysis Runs J 81. K 200 Mesh Run M +200 -l00 Mesh Poroslty Settlng Microns Porosity Setting Microns .80 1.95 .75 8.40 .75 1.50 .70 6.40 .70 1.83 .65 6.40 .65 2.04 .62 1.90 Run L 200 Mesh Run N +200 l00 Mesh Porostt Setttn MICI'OIIS Porosity Setting Microns .80 0.90 .80 7 .75 1.10 .75 8 .70 1.30 .70 6.8 .65 1.48 .65 5.9 .62 (1.60 1.45 .60 5.3 Run M -'00 Mesh Run M +200 200 50/50 Porosn Settin M crons Porosity Setting Microns .30 1. 5 .80 7.20 .75 1.25 .75 5.20 .70 1.55 .70 3.05 .65 1.51 .65 2.45 .62 1.65 .62 2.35 .62 2.35 Run N -200 Mesh Run N +200 -20O 50/50 Poroslt Setttn M" Porosit Settin product of the capacitance and test voltage per unit weight of anode material. The tests indicate that the CV product per gram is comparable to powders in commercial use.

Anodes sintered at 1900C gave CV/g values in the approximate range 2,9003.360 and with a 2,000 sinter. 2,400-2,600. At a sintering temperature of l,800, CV/g of approximately 4000-5 .100 were found.

The DC leakage current was one-quarter to one-half microampere in anodes sintered at 2,000.

Using the apparatus depicted in FIG. 4, several runs were conducted to test the efficacy of the method and device in the continuous production of elemental refractory metals. The feed material consisted of columbium pentachloride fluidized with argon carrier gas. The reductant consisted of hydrogen.

After a period of running time a metallic sponge formed on the collector cup 152. The cup was lowered and rods 156 inwardly positioned to rake off the formation product when the cup 152 was moved back into its initial position. Formation product dropped into the receptacle 158. This procedure was repeated and the test then terminated.

The formation product was subjected to analysis and determined to be columbium. Of total theoretical recovery, 81.5 percent of the columbium was recovered in the sponge donut form, while 17.8 percent of the metal was additionally recovered for a total overall recovery of 99.3 percent. Spectographic analysis indicated that the columbium was of pure form as follows:

Impurity Wt. 70

Si .006 Mm trace Fe trace Mg trace Ca trace Al .02 Cu .05 Ti .08

Wet Analysis Cl 05% J50 The efficacy of the apparatus and method of the invention, as well as the range of applicable chemical reactions, was demonstrated by several experimental runs accurately tabulated in Table V.

The blade member 226a, as seen in FIG. 7A is of somewhat rectangular configuration having an edge or end portion 230 of the same radius as the radius ofthe member 216 so as to form a crescent shape gap 236 best seen in FIG. 7. The blade member 226a is provided with a water or other coolant passageway 227 having appropriate cooling source connections wherein the coolant is introduced through inlet 229 and circu lated through outlet conduit 23]. The cooling feature of the blade 226a aids in collection of the desired end product.

Referring again to the remaining figures of drawings, it will be seen that the chamber 210 is provided with an opening 238 into a product collection member 240. Projecting into the chamber 214 and disposed above TABLE V Sponge Head H Stab. Feed Carrier Metal of Effy Flow, SCFH Flow, SCFH Feed Recovd. theoretical Run No. l 26 595 47 (Ar) WO 246g. 40.7 Run No. 2 56.6 883 I98 (Ar) (NI-I,),,M0 2487g. 86

Run No.9 66.7 883 I98 (Ar) (NH,) 10"12 4335g. 90.3

Referring now to FIGS. -10 inclusive of yet another apparatus is shown wherein the practice of the method of the invention whether it be for the reduction of metallic salts, the chlorination of metallic oxides, the formation of metal alloys or the high temperature synthesis of chemical compounds on a continuous basis without the need of shutting down the plasma reactor is shown.

The apparatus 200 employs a typical plasma generator head 202 having feed inlets 204 communicating to a reaction zone 206 with a quench or collection zone 208 therebelow.

An encompassing chamber 210 having water circulation paths 212 through which water or other cooling medium is circulated forms a chamber 214 within which the reaction zone 206 and collection 208 formed by tungsten line member 216 is contained. The member 216 is supported by vertical support member 218 but is mounted for reciprocal movement (as seen in FIGS. 9 and upon the support plate 220. The member 216 is provided with moving handle or means 222 by which the member 216 may be moved to the far left position as seen in FIG. 5 and as schematically illustrated in FIG. 9.

The member 216 in this instance, is of cylindrical configuration and is provided with opening 224 into which projects blade member 226 which is reciprocally mounted for varying a gap 228 formed between the edge 230 of blade 226 and the interior wall 232 of member 216.

Blade member 226 in this instance, may be Of-graphite and provides the means whereby a pressure differential and temperature gradient is obtained between reaction zone 206 and collection zone 208. The blade member 226 is also connected to manipulating means 234 which permits the wide variety of lateral adjustments (as seen in FIG. 5) so that the practice of the invention, whether it be for reduction, chlorination or synthesis will provide the means whereby a desired end product is obtained. In some instances, the blade member 226 may be of an inert metal, i.e., tungsten or the like, and may be itself water cooled as seen in FIG. 7A.

the collector 240, is a rotatable auger 242 which provides for ease of collection of the product, for example, the elemental metals where the process carried out is the formation of same.

The member 216 is provided with effluent outlet 244 which communicates to a cyclone collector member, not shown, through conduit member 246. Other specifics of the construction of the chamber member 210 are not important and form no part of the invention except as is necessary to carry out practice of the invention and employs the type of plasma reactor head as previously disclosed and generally operates under the same parameters as set forth for the FIGS. 3 and 4 apparatuses using essentially the same method except as will now be described.

In the utilization of the apparatus 200, a passage of reaction time permits the formation of, for example, tantalum sponge metal on the blade member 226, particularly in the gap area 228 as shown in FIG. 5. Whereas, the apparatus of FIG. 3 would have to be shut down in order to reclaim the reaction product, the apparatus 200 is not so limited.

Referring now to FIGS. 9 and 10, it will be seen that after the formation of a sufficient amount of reaction product, the member 216 is withdrawn in the direction of the left hand arrow cleaning off product accumulation that has formed on the blade member 226 and continual movement of the member 216 along the support plate 220 positions it under the auger cleanout means 242 as seen in FIG. 10. The FIG. 9 illustration shows the auger member 242 in the uppermost non-cleaning position. However, when the member 216 is in proper position, the auger member 242 is lowered and is rotated so as to clean accumulated product from the reaction zone 206 and collection zone 208 so that it falls into the opening 238 and thence into collector means 240.

After the scraping or cleaning has been accomplished, the means 242 is simply withdrawn to the uppermost position as shown in FIGS. 5 and 9 and the member 216 moved back into process position by means of handle or drive means 222 as shown in FIG.

and the collection process resumed by the disposition of blade 226 into the interior of member 216 all without interruption by a prolonged period of time and all without shutting down the reactor 202 so that the process utilizing the apparatus 200 is almost a continuous one.

Referring now to FIGS. 11 and 12, a more sophisticated apparatus will now be described which differs little from the process of the invention hereinabove referred to and excels over the apparatus shown in FIGS. 5 et seq. in that little interruption is involved in carrying out the process such that it is a continuous one for all practical purposes Referring to FIGS. 11 and 12, it will be seen that the apparatus 300 provides for practice of the invention on a continuous process basis as will now be described.

During normal operation, feed material is introduced into the plasma stream emanating from the plasma generator assembly 302. The feed material enters the reaction zone 304 through four tubular ports equally spaced around, and inclined toward, the plasma stream. As previously described, reduction of the feed material by the reducing gas which forms the plasma takes place in the reaction zone 304 which is the volume formed by the throat 306 above the blade 308, when in the dotted line operative position.

At the beginning of the reaction cycle, the blade 308 is fully extended into the slot 310 in the throat 306, nearly making contact with the side of the throat 306 opposite the slot 310. This ensures proper pressure drop (about 3 psi differential) across the gap 312 formed by the blade 308 and the interior wall of the throat 306. As metal sponge, for example, begins to form and fill the gap 312, a differential pressure sensor (not shown) signals the blade lead screw drive motor (not shown) to slowly withdraw the blade 308 until the pressure inside the reaction zone 304 is reduced to its preset level (about 3 psi differential).

When the blade 308 has been withdrawn to a predetermined point, or when the metal sponge deposit has increased to such an extent that the pressure in the reaction zone can no longer be controlled by retraction of the blade 308, feeding of the reactants is terminated, the blade 308 is completely withdrawn from the throat 306, as seen in full line, and the pneumatic throat clamp assembly 314 lowers the rotary throat assembly 316 which supports both throats 306 and 318. When the top 320 of throat 306 is clear of the quench top 322, a rotary pneumatic actuator (not shown) rotates the rotary throat assembly 324 one half turn (from left to right as seen in FIG. 12). This action permits the throat 306 containing the newly deposited metal sponge to be positioned under the boring mechanism assembly 326 mounted on the quench top 328. At the same time, a clean throat 318 is moved from its position under the boring mechanism assembly 326 to a position under the plasma head assembly 302. When this movement is complete, the throat clamp assembly 314 raises the rotary throat assembly 324 until the throats 306 and 318 are clamped against the quench tops 322 and 328. This action signals the throat slide actuators 330 to move the throat slide 332 from one end A of the rotary throat assembly 324 to the end B (FIG. 12). The throat slide 332 is channel mounted on assembly 324 to form one end of the collector zone 331.

The base plate 334 of therotary throat assembly 316 is provided with an opening 336 under the throats 306 and 318 to permit removal of the formed metal sponge. However, it is necessary to seal these openings during the reaction phase of the cycle. This is accomplished by the throat slide 332 which is positioned "by the throat slide actuator 330. After the rotary throat assembly 324 has been rotated and clamped to the quench top 322 the throat slide actuators 330 reposition the throat slide 332 under the throat located under the plasma head assembly 302.

Thereafter, the blade 308 is moved into the slot 310 in the throat 306. When the blade 308 has fully penetrated into the throat 306 a feed metering assembly introduces feed material into the reaction zone 304, beginning a new reaction cycle. At the time the blade 308 begins to enter the slot 310 of one throat 306, for example, the boring mechanism 338 begins to clean the metal sponge deposit from the other throat 318.

The boring mechanism 338 consists of the electric motor chain-driving a pair of ball-bearing nuts which ride on ball screws fastened to the boring assembly base plate 326. As the nuts rotate, the motor and nut assembly is caused to move downward. Simultaneously, an extension 340 of the motor shaft projecting into the throat 3l8 through a packing gland 342 in the quench top 328, is rotated by the boring assembly motor. This combined rotation and downward travel causes crossbar 344 fastened to the shaft extension, to sweep the interior of the throat 318, breaking loose the deposits of metal sponge, which fall through the hole 336 in the rotary throat assembly 324 and into the sponge collector 346 located below the boring mechanism 338.

Adjacently positioned to the throat to be cleaned" is blade slot and effluent clean out mechanism 350. The mechanism 350 is pneumatically operated for reciprocal movement from left to right as seen in FIG. 11, to effect removal of plugs of metal sponge or the like that has accumulated in the blade slot 310 and effluent ports 349 located in each of the throats 306 and 318.

The gaseous products of the reaction flow past the blade 308 and out through the quench exhaust tube 348. Entrained in this gas stream is the fraction of the metal not captured as sponge at the gap 312 formed by the blade 308 and the throat 306. Removal of the major part of this gas-entrained metal powder is accomplished as the gas stream flows into a cyclone collector system (not shown).

The apparatus 300 may also be provided with win dow 352 for visual observation and is provided with window shutter 354 which is pivotally mounted to cover over window 352. Should the need arise. wherein the reactor head 302 must be removed, and in order to prevent foreign matter from entering the quench or reaction zones, shutter 356 is pivotally affixed for positioning over the opening formed by removal of the plasma generator 302.

The means of accomplishing the actuation of the various components of apparatus 300 are within the skill of the ordinary worker of the art and form no part of the herein-disclosed invention, and thus. further reference to same will not be made.

Using apparatus as depicted in FIG. 3, a series of runs were made to ascertain the efficacy of the invention in the halogcnution of columhiurn oxide. The apparatus employed a carbon lined reaction zone with a carbon collector means. The following Table VI accurately d8- picts the result of an exemplary run wherein columbium pentoxide was reacted with carbon tetrachloride to produce columbium chloride ucts, (graphite for example) high temperature chemical reactions may be carried out. Under such condi- TABLE VI Stabilizer Feed Carrier Feed Recov'd By- Gas Gas Material Product Product RUN A Argon, Argon Cb O CbCl CO, Cl

Nitrogen CCl Spectographic analysis confirmed the recovery of a yellow powder of columbium pentachloride.

Another test was conducted in order to establish the ability to form a metal alloy using the method and apparatus of the invention. The results of this test are emhm tions, synthesis, halogenations and other high temperature reactions may be carried out to increase yields of desired end products using a minimum of conversion energy.

Methane is introduced into the reactor while maintaining a pressure differential in the reaction zone of TABLE VI] Stabilizer Feed Carrier Feed Recovd By Gas Gas Material Product Product RUN B Argon. Argon CbCl Cb -,Sn HCl Hydrogen SnCl- X-ray diffraction analysis confirmed the identity of the recovered product.

Still another test was conducted to ascertain the effectiveness of removing contaminating oxides from tungsten sludge.

Another series of tests were run using the apparatus of FIGS. 5-10, to reduce ammonium paratungstate (APT) to the elemental metal. These runs are shown in TABLE VIIl. The reaction zone was graphite with a tungsten lining and the blade was graphite.

TABLE VIII RUN Stablizer Feed Carrier Feed Recovd By- Gas Gas Material Product Product C Hydrogen Argon APT Tungsten H O, N 0 D Hydrogen Argon APT Tungsten H O, N. O. E Hydrogen Argon APT Tungsten H O, N 0 F Hydrogen Argon APT Tungsten H O, N 0

The use of a cooled blade, as shown in FIG. 7A was found to permit the development of small or fine particles of the metal, while an uncooled blade allowed recovery of particles having a micron size range considerably larger than when the blade is cooled by water or other coolants.

Use of the apparatus and method of the invention is also suitable for halogenation. For example, a feed material of columbium oxide is fed to the reaction using nitrogen for the plasma generation and either carbon tetrachloride or carbon andchlorine is fed into the reaction zone. The product obtained is columbium chloride which is then recycled through the reactor but using a reductant such as hydrogen. The columbium chloride is reduced to yield columbium in the elemental metal form. Likewise, a mixture of columbium oxide and tin oxide is subjected to chlorination which product is then reduced to produce an alloy mixture of columbium and tin.

Using the invention and apparatus of the invention wherein a fixed gap reaction zone is maintained, (because of the gaseous state of the reactants) and utilizing a reaction zone lined with materials that are inert under reaction actions and to the desired end, reaction prodvariations and modifications may be effected without departing from the essence and scope of the invention hereof.

We claim:

1. In a plasma apparatus, the combination of:

a. A plasma generator having a cathode and an anode within which a plasma arc is generated;

b. A reaction zone member communicating to said generator into which reactant feed material is introduced downstream of said anode;

c. A quench member communicating to said reaction zone through which reaction zone effluent flows; and

d. Means within said reaction zone member forming a selectively variable passageway or gap through which said effluent is directed in order to collect a selected product of reaction therefrom.

2. The'apparatus in accordance with claim 1 wherein said reaction zone member is adapted to establish a temperature gradient and pressure differential for said effluent.

3. The apparatus in accordance with claim 2 wherein said temperature gradient is produced by a portion of said reaction zone member being of larger size than the remainder thereof located upstream of the enlarged portion.

4. The apparatus in accordance with claim 3 wherein said enlarged portion opens into and communicates with said quench member in substantially fluid-tight relationship.

5. The apparatus in accordance with claim 4 wherein said quench member is tubular and communicates with an effluent outlet.

6. The apparatus in accordance with claim 5 wherein said enlarged portion is bell-shaped and a depending portion of said reaction zone member extends therelnto.

7. The apparatus in accordance with claim 6 wherein said collector means is cup-like in configuration and is axially shiftable substantially the effective length of said quench member.

8. The apparatus in accordance with claim 7 wherein said reaction zone member collector and at least the interior of said quench member through which said collector means is shiftable are fabricated of materials inert to reaction conditions and formed product.

9. The apparatus in accordance with claim 8 wherein said inert material is tungsten and a plurality of laterally extensible means are positioned in the wall of said quench member to engage product collected on said collector means.

10. The apparatus in accordance with claim 2 wherein said variable passageway is formed by a blade member projecting into said reaction zone member and terminating adjacent the interior wall thereof.

11. The apparatus in accordance with claim 10 wherein said reaction zone and quench members are continuous and said blade member forms reaction and quench zones.

12. The apparatus in accordance with claim 11 wherein a unitary member forms said reaction zone msmbera flsve m a rs...

13. The apparatus in accordance with claim 12 wherein said blade member is adapted for the circulation of a coolant to reduce the temperature thereof relative to said reaction zone member.

14. The apparatus in accordance with claim 12 wherein said blade member is mounted for total retraction from said unitary member.

15. The apparatus in accordance with claim 14 wherein said unitary member is positioned below said plasma generator.

16. The apparatus in accordance with claim 15 wherein said unitary member is movably positionable vertically and laterally with respect to said plasma gen- .erator.

17. The apparatus in accordance with claim 16 wherein said plasma apparatus is chambered to allow positioning of said unitary member adjacent said plasma generator.

18. The apparatus in accordance with claim 17 wherein said plasma apparatus is provided with a reaction product receiving member over which said unitary member is positionable.

19. The apparatus in accordance with claim 18 wherein said reactor apparatus is provided with a reaction product removal means to remove said reaction product from the interior of said unitary member.

20. The apparatus in accordance with claim 19 wherein said removal means comprises a rotatable member adapted to travel substantially the extent of the interior of said unitary member, whereby reaction product is removed and delivered to said reaction product receiving member.

21. The apparatus in accordance with claim 15 which comprises two unitary members mounted for sequential positioning beneath said reactor.

22. The apparatus in accordance with claim 21 wherein said two unitary members are mounted on a rotatable member.

23. The apparatus in accordance with claim 22 wherein said reactor apparatus is provided with a reaction product receiving member and each of said unitary members are positionable with respect thereto.

24. The apparatus in accordance with claim 23 wherein said unitary members are rotatable to be superposed said reaction product receiving member. and reaction product removal means is provided to remove said reaction product from the interior of said unitary member.

25. The apparatus in accordance with claim 24 wherein said removal means comprises a rotatable member adapted to travel substantially the extent of the interior of said unitary member positioned therebelow wherein reaction product is removed and delivered to said reaction product receiving member.

26. The apparatus in accordance with claim 25 wherein said reactor apparatus is chambered and is provided with a shutter member to isolate said reactor from the interior of the chambers.

27. The apparatus in accordance with claim 26 wherein laterally positioned and movable means is provided to remove reaction product from the exit and blade ports of said unitary members when one said unitary member is positioned over said reaction product receiving member.

28. The apparatus in accordance with claim 27 wherein said blade is adapted to have a coolant circulated therein. 

1. In a plasma apparatus, the combination of: a. A plasma generator having a cathode and an anode within which a plasma arc is generated; b. A reaction zone member communicating to said generator into which reactant feed material is introduced downstream of said anode; c. A quench member communicating to said reaction zone through which reaction zone effluent flows; and d. Means within said reaction zone member forming a selectively variable passageway or gap through which said effluent is directed in order to collect a selected product of reaction therefrom.
 2. The apparatus in accordance with claim 1 wherein said reaction zone member is adapted to establish a temperature gradient and pressure differential for said effluent.
 3. The apparatus in accordance with claim 2 wherein said temperature gradient is produced by a portion of said reaction zone member being of larger size than the remainder thereof located upstream of the enlarged portion.
 4. The apparatus in accordance with claim 3 wherein said enlarged portion opens into and communicates with said quench member in substantially fluid-tight relationship.
 5. The apparatus in accordance with claim 4 wherein said quench member is tubular and communicates with an effluent outlet.
 6. The apparatus in accordance with claim 5 wherein said enlarged portion is bell-shaped and a depending portion of said reaction zone member extends thereinto.
 7. The apparatus in accordance with claim 6 wherein said collector means is cup-like in configuration and is axially shiftable substantially the effective length of said quench member.
 8. The apparatus in accordance with claim 7 wherein said reaction zone member collector and at least the interior of said quench member through which said collector means is shiftable are fabricated of materials inert to reaction conditions and formed product.
 9. The apparatus in accordance with Claim 8 wherein said inert material is tungsten and a plurality of laterally extensible means are positioned in the wall of said quench member to engage product collected on said collector means.
 10. The apparatus in accordance with claim 2 wherein said variable passageway is formed by a blade member projecting into said reaction zone member and terminating adjacent the interior wall thereof.
 11. The apparatus in accordance with claim 10 wherein said reaction zone and quench members are continuous and said blade member forms reaction and quench zones.
 12. The apparatus in accordance with claim 11 wherein a unitary member forms said reaction zone member and quench member.
 13. The apparatus in accordance with claim 12 wherein said blade member is adapted for the circulation of a coolant to reduce the temperature thereof relative to said reaction zone member.
 14. The apparatus in accordance with claim 12 wherein said blade member is mounted for total retraction from said unitary member.
 15. The apparatus in accordance with claim 14 wherein said unitary member is positioned below said plasma generator.
 16. The apparatus in accordance with claim 15 wherein said unitary member is movably positionable vertically and laterally with respect to said plasma generator.
 17. The apparatus in accordance with claim 16 wherein said plasma apparatus is chambered to allow positioning of said unitary member adjacent said plasma generator.
 18. The apparatus in accordance with claim 17 wherein said plasma apparatus is provided with a reaction product receiving member over which said unitary member is positionable.
 19. The apparatus in accordance with claim 18 wherein said reactor apparatus is provided with a reaction product removal means to remove said reaction product from the interior of said unitary member.
 20. The apparatus in accordance with claim 19 wherein said removal means comprises a rotatable member adapted to travel substantially the extent of the interior of said unitary member, whereby reaction product is removed and delivered to said reaction product receiving member.
 21. The apparatus in accordance with claim 15 which comprises two unitary members mounted for sequential positioning beneath said reactor.
 22. The apparatus in accordance with claim 21 wherein said two unitary members are mounted on a rotatable member.
 23. The apparatus in accordance with claim 22 wherein said reactor apparatus is provided with a reaction product receiving member and each of said unitary members are positionable with respect thereto.
 24. The apparatus in accordance with claim 23 wherein said unitary members are rotatable to be superposed said reaction product receiving member, and reaction product removal means is provided to remove said reaction product from the interior of said unitary member.
 25. The apparatus in accordance with claim 24 wherein said removal means comprises a rotatable member adapted to travel substantially the extent of the interior of said unitary member positioned therebelow wherein reaction product is removed and delivered to said reaction product receiving member.
 26. The apparatus in accordance with claim 25 wherein said reactor apparatus is chambered and is provided with a shutter member to isolate said reactor from the interior of the chambers.
 27. The apparatus in accordance with claim 26 wherein laterally positioned and movable means is provided to remove reaction product from the exit and blade ports of said unitary members when one said unitary member is positioned over said reaction product receiving member.
 28. The apparatus in accordance with claim 27 wherein said blade is adapted to have a coolant circulated therein. 